2.6 Materiales compuestos
2.6.4 Clasificación de materiales compuestos según su refuerzo
PART TORQUE
PART Nm kgm
Under-basement fastening screws to cylinder block (see Figure 96)♦
Outer screws First stage : pre-tightening M10x1.25 25 2.5
Inner screws Second stage : pre-tightening M16x2 140 14
Inner screws Third stage : angle closing M16x2 60°
Inner screws Fourth stage : angle closing M16x2 60°
Outer screws Fifth stage : angle closing M10x1,5 90°
Pipe union for piston cooling nozzle M12X1.5 35± 2 3.5± 0.2
Intercooler fastening screws to cylinder block ♦ (see Figure 101) pre-tightening
Spacer and oil sump fastening screws (see Figure 102) 41.5± 3.5 4.1± 0.3
Gearcase fastening screws to cylinder block M10X1.25 41.5± 3.5 4.1± 0.3
M12X1.75 63± 7 6.3± 0.7
M8X1.25 23.5± 1.5 2.3± 0.1 Cylinder head fastening screw: (see Figure 97)
First stage pre-tightening 50 5
Second stage pre-tightening 100 10
Third stage angle closing 90°
Fourth stage angle closing 75°
Rocker arm shaft fastening screw♦ (see Figure 98)
First stage pre-tightening 40 4
Second stage angle closing 60°
Locknut for rocker arm adjusting screw♦ 39± 5 3.9± 5
Screws for injector fastening brackets♦ 36.5 3.65
Shoulder plate fastening screws to head♦ 20± 2 2± 0.2
Engine support bracket fastening screws to cylinder head 74± 8 7.4± 0.8
Gear fastening screws to camshaft:♦
First stage pre-tightening 50 5
Second stage angle closing 50°
Phonic wheel fastening screws to distribution gear 8.5± 1.5 0.8± 0.1
Exhaust pipe fastening screws• (see Figure 99) pre-tightening
Engine brake actuator cylinder fastening screws 19± 3 1.9± 0.3
Connecting rod cap fastening screws:♦
First stage pre-tightening 50 5
Second stage angle closing 40°
Engine flywheel fastening screws:♦ M16x1.5x58
First stage pre-tightening 100 10
Second stage angle closing 60°
Engine flywheel fastening screws:♦ M16x1.5x110
First stage pre-tightening 100 10
Second stage angle closing 120°
Flywheel pulley fastening screws to crankshaft :♦
First stage pre-tightening 70 7
Second stage angle closing 50°
♦ Lubricate with oil MOLYKOTE before assembly
• Lubricate with graphitized oil before assembly
PART TORQUE
PART Nm kgm
Damper flywheel fastening screws:♦ 115± 15 11.5± 1.5
Idler gear pin fastening screws:♦
First stage pre-tightening 30 3
Second stage angle closing 90°
Idle gear link rod fastening screw 24.5± 2.5 2.4± 0.2
Oil pump fastening screw 24.5± 2.5 2.4± 0.2
Oil pump suction rose fastening screw 24.5± 2.5 2.4± 0.2
Front cover fastening screw to cylinder block♦ 19± 3 1.9± 0.3
Control unit fastening screw to cylinder block♦ 19± 3 1.9± 0.3
Supply pump fastening screw to gearcase♦ 19± 3 1.9± 0.3
Fuel filter support fastening screw to cylinder head 24.5± 2.5 2.4± 0.2
M16x2 screw securing engine support to gears box♦
First stage pre-tightening 100 10
Second stage angle closing 60°
Turbo-compressor fastening screws and nuts• (see Figure 100) pre-tightening
tightening
35± 5
46± 2 3.5± 0.5 4.6± 0.2
Water pump fastening screw to cylinder block 24.5± 2.5 2.4± 0.2
Pulley fastening screw to hub 55± 5 5.5± 0.5
Rocker arm cover fastening screws (see Figure 103) 9 0.9
Thermostat box fastening screws to cylinder head 24.5± 2.5 2.4± 0.2
Automatic tightener fastening screws to cylinder block 45± 5 4.5± 0.5
Fixed tightener fastening screws to cylinder block 105± 5 10.5± 0.5
Fan support fastening screws to cylinder block 24.5± 2.5 2.4± 0.2
Starter fastening screws 44± 4 4± 0.4
Air heater on cylinder head 50± 5 5± 0.5
Air compressor fastening screw to cylinder head 74± 8 7.4± 0.8
Air compressor control gear fastening nut 170 17± 1
Hydraulic power steering pump gear fastening nut 46.5± 4.5 4.6± 0.4
Air conditioner compressor fastening screw to support 24.5± 2.5 2.4± 2.5
Air conditioner compressor support fastening screw to cylinder block 44± 4 4.4± 0.4
Alternator support fastening screw to cylinder block 44± 4 4.4± 0.4
Alternator bracket fastening screw to cylinder block 24.5± 2.5 2.4± 0.2
Water pipe unions 35 3.5
Water temperature sensor 32.5± 2.5 3.2± 0.2
♦ Lubricate with oil MOLYKOTE before assembly
• Lubricate with graphitized oil before assembly
PART TORQUE
PART Nm kgm
Engine brake solenoid valve fastening screws 32.5± 2.5 3.2± 0.2
Flywheel rev sensor fastening screw 8± 4 0.8± 0.2
Camshaft rev sensor fastening screw 8± 2 0.8± 0.2
P.D.E solenoid connector fastening screw 1.62± 0.3 0.1± 0.3
Overboost pressure sensor fastening screw 8± 2 0.8± 0.2
Absolute pressure sensor fastening screw 22.5± 2.5 2.2± 0.2
P.W.M. control valve fastening screw/nut 8± 2 0.8± 0.2
Fuel/coolant temperature sensor 35 3.5
Coolant temperature indicator 23.5± 2.5 2.3± 0.2
Filter clogging sensor 10 1
Oil temperature switch 25± 1 2.5± 0.1
Oil pressure sensor 25± 1 2.5± 0.1
Oil clogging sensor 55± 5 5.5± 0.5
Electric wire fastening screw 8± 2 0.8± 0.2
Heater fastening screw:
M14X70/80 screw securing front and rear spring blocks to chassis 192.5± 19.5 19.2± 1.9 M16X130 screw securing front and rear spring blocks to engine 278± 28 27.8± 2.8 M18X62 flanged hex screw for front engine block:
First stage pre-tightening 120 12
Second stage angle closing 45°
M14X60 socket cheese-head screw for front engine block:
First stage pre-tightening 60 6
Second stage angle closing 45°
Flanged hex screw for rear engine block:
First stage pre-tightening 100 10
Second stage angle closing 60°
44898
FRONT SIDE Front phase:
angle tightening of inner screws
60º
44897
44899 44898
Figure 96
First phase:
preliminary tightening of outer screws
(25 Nm)
FRONT SIDE
FRONT SIDE
Second phase:
preliminary tightening of inner screws (140 Nm)
Fifth phase:
angle tightening of outer screws
90º
44898
FRONT SIDE Third phase:
angle tightening of inner screws
60º FRONT SIDE
Underblock fixing screws tightening sequence
44900
Figure 97
Figure 98
Diagram of exhaust manifold fixing screws tightening sequence
45359
Diagram of cylinder head fixing screws tightening sequence
1 8
6 3 2 7 6 3 4 7 6 3 2 7
5 4
8 5
2 8
5
4 1 1
Figure 99
70567A
Diagram of rocker shaft fixing screws tightening sequence
455361
Figure 100
Figure 101
Diagram of engine oil sump fixing screws tightening sequence
45362
Diagram of heat exchanger fixing screws tightening sequence
1
8
12 11 10 3
9 13
14
4 5 6 7 2
Figure 102
SEQUENCE: Preliminary tightening 4 - 3 - 1 - 2
Tightening 1 - 4 - 2 - 3
45360
Diagram of turbocharger fixing screws and nuts tightening sequence
Figure 103
Diagram of rocker arm cap fixing screws tightening sequence
45363
17 14 13 1 4 5 8
18 19 20
16 15 12 2 3 6 7
11
10
9
SECTION 5 Tools
Page TOOLS . . . 3
TOOLS
TOOL NO. DESCRIPTION
8093731 Tester PT01
99305019 Full-optional tool-kit to rectify valve seat
99305047 Equipment for spring load check
99322230 Rotary telescopic stand
99340051 Extractor for crankshaft front gasket
99340052 Extractor for crankshaft rear gasket
TOOLS
TOOL NO. DESCRIPTION
99340205 Percussion extractor
99342148 Injector extractor
99342149 Extractor for injector-holder
99346245 Tool to install the crankshaft front gasket
99346246 Tool to install the crankshaft rear gasket
99348004 Universal extractor for 5 to 70 mm internal components
TOOLS
TOOL NO. DESCRIPTION
99350072 Box wrench for transmission gear support fixing screws
99350074 Box wrench for block junction bolts to the underblock
99360144 Skid retaining tools (12+6) for rocker arm adjusting screws during rocker arm shaft removal/ refitting
99360177 Injector housing plug
99360184 Pincers for removing and refitting circlips and pistons (105-160 mm)
99360264 Tool to take down-fit engine valves
TOOLS
TOOL NO. DESCRIPTION
99360288 Tool to remove valve guide
99360292 Tool to install gasket on valve guide
99360294 Tool to drive valve guide
99360314 Tool to remove cartridge filters
99360321 Tool to rotate engine flywheel
99360334 Tool for checking cylinder barrel projection.
TOOLS
TOOL NO. DESCRIPTION
99360335 Cylinder barrel compression cap (to be used with 99360334)
99360351 Tool to stop engine flywheel
99360487 Tool to take down and fit back camshaft bushes
99360500 Tool to lift crankshaft
99360551 Bracket to take down and fit engine flywheel
99360558 Tool to lift and transport rocker shaft
TOOLS
TOOL NO. DESCRIPTION
99360585 Balance for lifting and handling engine
99360605 Belt to insert piston in cylinder liner (60 - 125 mm)
99360612 Engine flywheel timing pin
99360613 Tool for timing of phonic wheel on timing gear
99360703 Tool to stop cylinder liners
99360706 Tool to extract cylinder liners
TOOLS
TOOL NO. DESCRIPTION
99360724 Tool to extract the cylinder liners (to be used with 99360723)
99361035 Brackets fixing the engine to rotary stand 99322230
99365054 Tool for injector holder heading
99370415 Tool to detect cylinder liner projections (use with 99395603)
99378100 Tool for printing engine identification plates (to be used with special punches)
99378101 * 99378102• 99378105J 99378106Y
Punches (A * - B•- EJ - FY) for printing engine identification plates (to be used with 99378100)
TOOLS
TOOL NO. DESCRIPTION
99389834 Dynamometric screwdriver to calibrate screws for injector solenoid valve
99390310 Valve guide sleeker
99390772 Tool to remove residues from injector holder
99390804 Tool to thread injector holders to be extracted
99394014 Guide bush (to be used with 99394041 or 99394043)
99394041 Cutter to rectify injector holder housing (to be used with 99394015)
TOOLS
TOOL NO. DESCRIPTION
99394043 Reamer to rectify injector holder lower side (to be used with 99394015)
99395215 Gauge for centre distance check between camshaft and idle gear
99395216 Measuring pair for angular tightening with 1/2” and 3/4” square couplings
99395363 Complete square to check connecting rod squaring
99395603 Dial gauge (0 - 5 mm)
99395687 Reaming gauge (50-178 mm)
TOOLS
TOOL NO. DESCRIPTION
99396033 Centering ring of crankshaft front cap
Appendix
Page SAFETY PRESCRIPTIONS . . . 3
Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working area and whose non fulfillment will make any other measure useless or not sufficient to ensure safety to the personnel in-charge of maintenance.
Be informed and inform personnel as well of the laws in force regulating safety, providing information documentation available for consultation.
- Keep working areas as clean as possible, ensuring adequate aeration.
- Ensure that working areas are provided with emergency boxes, that must be clearly visible and always provided with adequate sanitary equipment.
- Provide for adequate fire extinguishing means, properly indicated and always having free access. Their efficiency must be checked on regular basis and the personnel must be trained on intervention methods and priorities.
- Organize and displace specific exit points to evacuate the areas in case of emergency, providing for adequate indications of the emergency exit lines.
- Smoking in working areas subject to fire danger must be strictly prohibited.
- Provide Warnings throughout adequate boards signaling danger, prohibitions and indications to ensure easy comprehension of the instructions even in case of emergency.
- Do not execute any intervention if not provided with necessary instructions.
- Do not use any tool or equipment for any different operation from the ones they’ve been designed and provided for: serious injury may occur.
- In case of test or calibration operations requiring engine running, ensure that the area is sufficiently aerated or utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning and death.
SAFETY PRESCRIPTIONS